Diaphragm lip and seal for fluid control valve and methods of fluid control

ABSTRACT

A fluid control valve includes a cover portion having a first channel and a body portion having a second channel. Inner surfaces of the cover and the body portion define a chamber that includes an inlet and an outlet in communication with the chamber. The fluid control valve also includes a diaphragm disposed between the cover portion and the body portion. The diaphragm has a flexible member that is disposed within the chamber for controlling communication between the inlet and the outlet and a lip member circumscribing the flexible member. When the cover portion and the body portion are joined, the first channel and the second channel define a cavity that circumscribes the chamber and the cavity is configured such that each channel receives a portion of the lip member and pinches the lip member to seal the fluid control valve and hold the diaphragm.

This international application claims the benefit of priority to U.S.Provisional Patent App. Nos. 62/433,453 filed Dec. 13, 2016, 62/433,488filed Dec. 13, 2016, 62/433,541 filed Dec. 13, 2016, and 62/433,572filed Dec. 13, 2016, each of which is incorporated herein by referencein its entirety.

BACKGROUND OF THE INVENTION

Diaphragm-type fluid control valves can provide controlled fluidseparation and flow along a pipe-line, manifold or other piping network.Generally, the diaphragm-type valve includes a flexible diaphragmelement to control fluid flow between the inlet and the outlet of thevalve body. More specifically, in known diaphragm-type valves, theflexible element engages a seat formed within the valve body to separatethe interior chamber of the valve body into three parts: (i) the inletchamber which can hold the supply fluid, (ii) and outlet chamber whichreceives fluid from the inlet chamber for discharge out the outlet and(iii) a diaphragm chamber which can hold a fluid under pressure tomaintain the diaphragm element in the seated position. Upon release offluid pressure from the diaphragm chamber, the diaphragm element can bedisplaced from the seated position by the pressure of fluid in the inletchamber and fluid flow is permitted between the inlet and the outletchambers.

To ensure the diaphragm seals properly, the above-describeddiaphragm-type valves require a bias force to urge the diaphragm towardsthe valve seat even when there is fluid pressure in the inlet chamber.This is because, in typical systems, the source of the fluid to thediaphragm chamber is the inlet of the valve itself. Thus, when thediaphragm chamber has fluid under pressure, the pressure in thediaphragm chamber is equal to the inlet. This means that, whilereleasing the fluid pressure in the diaphragm chamber opens the valve,when the pressure is restored to the diaphragm chamber, the forces oneach side of the diaphragm will be balanced until the diaphragm actuallyseats. Accordingly, to ensure the diaphragm is forced to the valve seat,a bias is needed to urge the diaphragm to the closed position. To thisend, International Patent Publication No. WO 2008/051871 discloses adiaphragm with an elastomeric ring element disposed near an outercircumference of the diaphragm to urge the diaphragm member to a closedposition. Specifically, the outer angled surface of the elastomeric ringelement engages and provides pressure contact with a portion of theinterior surface of the valve body to assist in urging the diaphragmtowards its sealing position to permit closure of the valve. Thediaphragm can also include one or more rib members and an interior ringdisposed in a central portion of the upper surface of the diaphragm tofurther urge the diaphragm to the seated position. Similarly, in U.S.Patent Application Publication No. 2005/0205815, the diaphragm isconfigured to include ribs and/or a ring that is attached to thediaphragm to bias the diaphragm towards the sealing position.Specifically, the upper face of the diaphragm has tangential ribs andradial ribs to urge the diaphragm towards the valve seat on the valvebody. In addition, the diaphragm also includes a flexible ring elementthat is in pressure contact with the body of the valve to urge thediaphragm towards the seat to close the valve. However, the design andmanufacturing process of the diaphragms will need to account for theribs and/or rings, which can produce added complexity and/or expense inmanufacture.

In some known valves, springs and/or other biasing devices engage thediaphragm such that, when the pressure in the diaphragm chamber isrestored and the forces balance, the spring (or another biasing device)can urge the diaphragm to the closed position. For example, in UK PatentApplication No. GB 2231126, a spring engages the diaphragm on an upperside of the diaphragm to force a lower side of the diaphragm to makecontact with the valve seat. Once contact is made, the forces, due tothe fluid pressures, are no longer balanced and the force on the upperside of the valve will be greater. However, to accommodate the spring,the upper cover of the valve must be made larger than needed and/orinclude features to receive the spring. In addition, at low rates, thebiasing device can create vibrations that damage the diaphragm. Further,separate biasing devices such as springs can complicate the assembly ofthe valve and add extra costs to the valve assembly. Moreover, theclosing force generated by the spring can produce an unacceptablepressure loss in the valve.

Moreover, in the above-discussed systems, the diaphragm is attached tothe valve by disposing a portion of the diaphragm between the coverportion and body portion and clamping the cover portion to the bodyportion. For example, the valve assembly can be securely connected usingbolts and/or threaded studs that clamp the cover portion to the bodyportion with the diaphragm disposed in the middle. However, in thetypical system, the bolts and/or threaded studs also go through thediaphragm, which has corresponding holes to receive the bolts orthreaded studs. Such an arrangement provides high stress concentrationson the diaphragm around the holes during the open/close cycles of thevalve. The stress on the diaphragm can lead to damage and prematurefailure of the diaphragm. WO 2015/181709 appears to disclose adeformable membrane that is clamped between two flanges without boltsgoing through the membrane. However, only one of the flanges has agroove or channel to receive the outer edge of the deformable membranewhile the other flange has a flat surface. Thus, one side of thedeformable membrane is pressed against the flat surface of the flangewhen the valve is assembled. Because one of the flanges has a flatsurface, the valve could be susceptible to leakage if there is a flaw orimperfection in either the flat surface of the flange or the deformablemember.

Further limitation and disadvantages of conventional, traditional, andproposed approaches to diaphragm-type valve configurations will becomeapparent to one skilled in the art, through comparison of suchapproaches with embodiments of the present invention as set forth in theremainder of the present disclosure with reference to the drawings.

SUMMARY OF THE INVENTION

Preferred embodiments of the present invention provide for a moreprecise control of the fluid flow and/or pressure in diaphragm-typecontrol valves by employing a diaphragm having a simple constructionwith minimal stress concentrations during operation. In one preferredembodiment, a fluid control valve includes a valve body with a coverportion and a body portion. The inner surfaces of the cover portion andthe body portion define a chamber. Preferably, the chamber has an axisand a plane substantially perpendicular to the axis. The chamberincludes an inlet and an outlet in communication with the chamber andthe inlet and outlet are substantially aligned along the axis. The fluidcontrol valve also includes a diaphragm disposed between the coverportion and the body portion. Preferably, the diaphragm has a flexiblemember that is disposed within the chamber for controlling communicationbetween the inlet and the outlet. In some embodiments, the diaphragmincludes a lip member circumscribing the flexible member. Preferably,the cover portion and the body portion each include a channel such that,when the control valve is assembled, the channels define a cavity thatcircumscribes the chamber of the control valve. The cavity is configuredto receive the lip member and engage with the lip member such that thecover portion and body portion pinch or squeeze the lip member tosecurely hold the diaphragm and seal the control valve when the coverportion and the body portion are securely connected. Preferably, bysecuring the lip member between the cover portion and the body portion,the lip member creates a tension force within the flexible member whenthe flexible member is in the inverted position due to the pressure onthe lower surface of the flexible member. Preferably, the cover portionis securely connected to the body portion using, e.g., bolts and/orthreaded studs. Preferably, the connecting means, e.g., the bolts and/orthreaded studs do not go through the diaphragm. Preferably, the bolt orthreaded stud pattern is disposed on the valve body such that the boltsand/or threaded studs do not penetrate diaphragm. That is, the boltsand/or threaded studs are disposed outside the outer perimeter ofdiaphragm.

Preferably, when the pressure in the diaphragm chamber is released, theflexible member has a natural-inverted or partially inverted position inwhich the flexible member is upturned inside-out due to the pressure onthe lower surface of the diaphragm. “Natural-inverted position” meansthe diaphragm shape in an inverted position corresponds to its naturalfull inverted state, for example, a hemisphere. When in thenatural-inverted or partially inverted position, preferably, the uppersurface conforms to a shape or profile of at least a portion of theinner surface of the cover to define a passageway that permitscommunication between the inlet and the outlet. “Conforms to” means thata surface of the flexible member generally follows the contour of anopposing surface and rests against at least a portion of the opposingsurface. “Rests against” as used herein means that a contact between asurface of the flexible member and a second surface is such that thesecond surface aids in supporting the flexible member. Preferably, wheninverted, the flexible member conforms to the inner surface of thecover. Preferably, at least a middle portion of the upper surface of theflexible member conforms to a profile of the inner surface of the coverportion when the flexible member is in the inverted position. In someembodiments, substantially the entire upper surface of the flexiblemember conforms to the profile of the inner surface of the coverportion. In some embodiments, the profile of the middle section of theinner surface of the cover portion can be a smooth concave surface.Preferably, the entire profile of the cover portion is a smooth concavesurface. In other preferred embodiments, the profile can have othertextures, shapes and/or contours.

The inner surface of the lower valve body can include one or moreelongated seat members. Preferably, each elongated seat member issubstantially aligned along the plane. Preferably, when in thenon-inverted position (lower position), the flexible member conforms toand seals against each elongated seat member so as to prevent fluidcommunication between the inlet and the outlet. Preferably, the lowersurface of the flexible member and each elongated seat member havecorresponding radius of curvatures such that the flexible memberconforms to and seals against each elongated seat member when theflexible member is in the non-inverted position (lower position).“Corresponding radius of curvatures” means a radius of curvature of thelower surface of the flexible member is substantially equal to a radiusof curvature of an elongated seat member and/or a radius of curvature ofa support member, as appropriate. For example, the radius of curvatureof the lower surface of the flexible member is within ±3% of the radiusof curvature of an elongated seat member and/or the radius of curvatureof a support member, as appropriate. Preferably, the correspondingradius of curvatures are within ±2.5%, more preferably within ±2.0%,even more preferably within ±1.0%, and still even more preferably within±0.5%. In some embodiments, the flexible member can include one or moreelongated members protruding from the lower surface. Preferably, whenthe flexible member is in its natural non-inverted position (lowerposition), each protruding elongated member contacts an elongated seatmember and seals against the seat member so as to prevent fluidcommunication between the inlet and the outlet. Once the protrudingelongated member makes contact with the elongated seat member, the forceon the upper surface of the flexible member will be greater than theforce on the lower surface and the flexible diaphragm will firmly seal.

Preferably, the diaphragm member includes a reinforced fabric embeddedin a rubber matrix. Because the reinforced fabric does not stretch asmuch as the rubber, a tension force is mostly concentrated in thereinforced fabric when the flexible member is forced to the invertedposition. In some embodiments, the diaphragm is constructed such that,when the diaphragm is in the inverted position, a tension force withinthe diaphragm is such that it exclusively biases the flexible member tothe lower position. “Exclusively biases” means that additional diaphragmstructures such as, e.g., ribs and rings and biasing devices such assprings are not used to urge the flexible member to the lower positionto seal against the elongated seat member.

Preferably, the flexible member has an upper surface having asubstantially smooth wall portion. For example, the upper surface canhave a constant radius of curvature and can be, e.g., bowl-shaped. Insome embodiments, the substantially smooth wall portion circumscribes asubstantially smooth central portion that, preferably, has an infiniteradius of curvature. For example, the central portion can be a flatsurface. The lower surface of the flexible member can have any texture.In some embodiments, the lower surface has a substantially smoothsurface except for at least one elongated member disposed on the lowersurface. “Substantially smooth” as used herein means a continuous levelsurface that has a constant radius of curvature or a slightly varyingradius of curvature that approximates a constant radius of curvaturewithout significant convex portions, or an infinite radius of curvatureor a substantially infinite radius of curvature approximating a flatsurface that is within manufacturing tolerances based the method ofmanufacture and the properties of the materials used for the diaphragm.For example, a diaphragm with a substantially smooth surface can includenon-functional features and structures such as, e.g., seams, minorimperfections, and minor variations in radius. In contrast, knowndiaphragms have ribs and/or other support structures, which means thatthe surface of the known diaphragms have numerous structures withvarying radius of curvatures.

The flexible member of the preferred control valve, preferably, axiallyseparates two sub-chambers from one another. Preferably adjacent each ofthe two axially separated sub-chambers is a diaphragm chamber forcontrolled operation of the diaphragm, i.e., controlled operation of theflexible member between the inverted and lower positions. The preferredorientation of the diaphragm chamber relative to the axially spacedchambers provides that the diaphragm chamber can seal the axially spacedsub-chambers from one another with a diaphragm fluid pressure that is atthe inlet sub-chamber pressure. Moreover, the preferred control valve,the diaphragm, and orientation of the sub-chambers provide for acontrolled seal between the axially spaced sub-chambers that cancompensate for fluctuations and surges in the fluid pressure in eitherof one of the two axially separated chambers. In one aspect, thepreferred control valve can be installed in piping systems, such as forexample, preaction fire protection systems that are known in the art.Thus, the preferred control valve can provide for a single andpreferably substantially constant pressure between the control valveand, e.g., a network of sprinklers. In some embodiments, the preferredcontrol valve includes an intermediate chamber in between the twosub-chambers. The intermediate chamber of the preferred control valvefills with pressurized fluid when the control valve is operated or thevalve seal is improper. Preferably, the intermediate chamber isconnected to an alarm. In some embodiments, the intermediate chamberprovides for a drain to atmosphere.

In some embodiments, the inner surface of the body portion preferablyincludes a bridge element substantially aligned along the plane andpreferably including a least two elongated seat members and a groovedisposed between the elongated seat members. A portion of the bodyportion further preferably defines a port in communication with thegroove. Preferably, the lower surface of the flexible member includes apair of spaced apart elongated members defining a channel therebetween.The elongated members of the flexible member preferably are in sealedengagement with the a least two elongated seat members when in thenon-inverted position such that the channel is in communication with thegroove and the port.

Accordingly, the various preferred embodiments of the preferablyhydraulically operated control valve, its diaphragm and method of usecan provide one or more of the following features: a design that employsa minimum number of moving components to reduce wear, a simplifiedflexible diaphragm configuration, a valve construction that facilitateseasy assembly and serviceability, and reliable performance.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, illustrate exemplary embodiments of theinvention, and, together with the general description given above andthe detailed description given below, serve to explain the features ofthe invention.

FIG. 1 is an exploded view of a preferred control valve.

FIG. 2 is an assembled cross-sectional view of the control valve of FIG.1 with the control valve in the closed position.

FIG. 2A is an assembled cross-sectional view of the control valve ofFIG. 1 with the control valve in the open position.

FIG. 2B is an assembled cross-sectional view of a bolt detail of thecontrol valve in FIG.

FIG. 3 is a perspective view of a preferred diaphragm for use in thecontrol valve of FIG. 1.

FIG. 3A is a plan-view of the upper surface of the diaphragm in FIG. 3.

FIG. 3B is a plan-view of the lower surface of the diaphragm in FIG. 3.

FIG. 3C is a cross-sectional view of the diaphragm along axis IIIC-IIICin FIG. 3B.

FIG. 3D is a cross-section view of the lip element in detail IIID of thediaphragm in FIG. 3C.

FIG. 3E is a cross-section view of the elongated member in detail IIIEof the diaphragm in FIG. 3C.

FIG. 3F is a cross-sectional view of the diaphragm along axis IIIF-IIIFin FIG. 3A.

FIG. 3G is a cross-section view of another embodiment of a lip element.

FIG. 4 is a perspective view of the lower valve body of the controlvalve in FIG. 1.

FIG. 4A is a top plan-view of the lower valve body in FIG. 4.

FIG. 4B is a cross-sectional view of the lower valve body along axisIVB-IVB in FIG. 4A.

FIG. 4C is a cross-sectional view of the lower valve body along axisIVC-IVC in FIG. 4A.

FIG. 4D is a cross-sectional view of the channel feature in detail IVDof FIG. 4C.

FIG. 4E is a cross-sectional view of another embodiment of a channelfeature for the body portion.

FIG. 5 is a perspective view of the cover of the control valve in FIG.1.

FIG. 5A is cross-sectional view of the cover along axis VA-VA in FIG. 5.

FIG. 5B is a cross-sectional view of the channel feature in detail VB ofFIG. 5A.

FIG. 5C is a cross-sectional view of another embodiment of a channelfeature for the cover portion.

FIG. 6 is cross-sectional perspective schematic view of the controlvalve of FIG. 1.

DETAILED DESCRIPTION

Exemplary embodiments of the present invention are directed to adiaphragm-type control valve with a simplified diaphragm configuration.Shown in FIG. 1 is an exploded view of the preferred valve 10 showingthe internal components of the valve 10. The valve 10 includes a valvebody 12 through which fluid can flow in a controlled manner. The controlvalve 10 is preferably configured for installation in a piping manifoldor other piping assembly to separate and control fluid flow between afirst fluid volume and a second fluid volume. For example, in a firesystem type application, the control valve 10 provides a diaphragm-typehydraulic control valve for preferably controlling the release andmixture of a first fluid volume having a first fluid pressure, such asfor example a water main, with a second fluid volume at a second fluidpressure, such as for example, compressed gas contained in a network ofpipes. Accordingly, the control valve 10 can provide fluid controlbetween fluids or various media including liquids, gasses orcombinations thereof.

The control valve 10 includes a valve body 12 preferably constructed intwo parts: (i) a cover portion 12 a and (ii) a body portion 12 b. “Bodyportion” is used herein as a matter of reference to a lower portion ofthe valve body 12 that is coupled to the cover portion 12 a when thecontrol valve is fully assembled. Preferably, the valve body 12 and morespecifically, the body portion 12 b includes an inlet 14 and outlet 16.Each of the inlet and outlet 14, 16 of the valve body 12 includes anappropriate end fitting for coupling to a manifold. For example, inlet14 preferably includes a coupling to a first fluid supply line, such asfor example a water main, and the outlet 16 also preferably includes acoupling to another pipe fitting such as, for example, a discharge pipecoupled to a network of interconnected pipes. The control valve 10 canbe installed in either a horizontal orientation such that fluid enteringthe inlet 14 at one elevation is discharged from the outlet 16 at thesame elevation, or alternatively, the control valve 10 can be installedin a vertical orientation such that fluid entering the inlet at oneelevation is discharged from the outlet at a different elevation.

The inlet 14, outlet 16 and valve body 12 can be sized so as to providea range of valve sizes for coupling to corresponding nominal pipe sizes.Preferably, the inlet 14, outlet 16 and valve body 12 define valve sizesof 1 inch (25 DN) and larger and more specifically valve sizes of 1 inch(25 DN), 1½ inch (40 DN), 2 inch (50 DN), 3 inch (80 DN), 4 inch (100DN), 6 inch (150 DN), 8 inch (200 DN), 10 inch (250 DN), and 12 inch(300 DN), which respectively accommodate nominal pipe sizes of 1 inch(25 DN), 1½ inch (40 DN), 2 inch (50 DN), 3 inch (80 DN), 4 inch (100DN), 6 inch (150 DN), 8 inch (200 DN), 10 inch (250 DN), and 12 inch(300 DN). However, other valve sizes that accommodate other nominal pipesizes can be provided. Preferably, in constructing the valve body 12,the cover portion 12 a and the body portion 12 b are separately cast andmachined to provide the preferred openings and surface treatments suchas threaded openings. However, other processes for construction andmanufacturing can be used. The valve body 12 is preferably cast fromductile iron however other materials may be used provided they aresuitable for a given fluid flow application. Preferably, a pressurerating of the valve 10 is about 300 psi (2.068 MPa).

In some embodiments, the valve body 12 can include a port 22 (see, e.g.,FIG. 4C) in the valve body 12 to provide means for an alarm systemmonitoring the valve for any undesired fluid communication from and/orbetween the inlet 14 and the outlet 16. For example, the port 22 can beused for providing an alarm port to the valve 10 so that individuals canbe alerted as to any gas or liquid leak from the valve body 12. Morespecifically, the port 22 can be coupled to a flow meter and alarmarrangement to detect the fluid or gas leak in the valve body. Inaddition, the port 22 is preferably open to atmosphere and, as discussedbelow, in communication with an intermediate chamber disposed betweenthe inlet 14 and the outlet 16. The port 22 can include an appropriatelythreaded opening or other mechanical fastening member for coupling anappropriate pipe fitting or nipple to the given orifice.

As shown in FIG. 1, disposed between the cover portion 12 a and the bodyportion 12 b is a diaphragm 100. The diaphragm 100 includes a flexiblepreferably elastomeric member 100 a, a lip member 100 b thatcircumscribes the flexible member 100 a, and a tab 100 c that is used toalign the diaphragm 100 in the control valve 10. The cover portion 12 aand the body portion 12 b each include an inner surface such that whenthe cover portion 12 a and body portion 12 b are joined together, theinner surfaces further define a chamber 24. As seen in FIG. 1, the bodyportion 12 b preferably includes a notch 49 for receiving the tab 100 cand properly aligning the diaphragm 100 within the chamber 24. In someexemplary embodiments, diaphragm 100 can have two or more tabs and thebody portion 12 b can have two or more corresponding notches foralignment purposes. In addition, because the bolts do not go through thediaphragm 100 to provide support, preferably pins (not shown), e.g., inthe tabs or another location, can be used to hold the diaphragm 100 inplace until the cover portion 12 a is attached when the valve 10 ismounted vertically. The chamber 24, being in communication with theinlet 14 and the outlet 16, further defines a passageway through which afluid, such as water, can flow. Disposed within the chamber 24 is theflexible member 100 a for controlling the flow of fluid through thevalve body 12. The flexible member 100 a provides selectivecommunication between the inlet 14 and the outlet 16.

The diaphragm 100 has at least two positions within the chamber 24: alower most fully closed or sealing position (see, e.g., FIG. 2) and anupper most or fully open position (see, e.g., FIG. 2A). As the diaphragm100 moves to the upper most or fully open position, the diaphragm 100and body portion 12 b define a passageway that permits communicationbetween the inlet 14 and the outlet 16. Preferably, at some pointbetween the fully closed position and the fully open position, across-sectional area of the passageway is such that there is sufficientflow through the control valve 10 and the pressure drop in the controlvalve 10 is minimized. Preferably, the diaphragm 100 is constructed soas to move to the natural-inverted position. In the natural-invertedposition, as seen for example in FIG. 2A, the flexible member 100 aconforms to at least the profile of the central section 33 (see FIG. 5A)of the first inner surface 17 of cover portion 12 a. In the lower mostclosed or sealing position, as seen for example in FIG. 2, the diaphragm100 engages a seat member 26 on bridge element 27 as seen in FIG. 4,which is constructed or formed as an internal rib or middle flangewithin the inner surface of the valve body 12, thereby sealing offcommunication between the inlet 14 and the outlet 16. With the diaphragm100 in the closed position (see FIG. 2), the diaphragm 100 preferablydissects the chamber 24 into at least three regions or sub-chambers 24a, 24 b and 24 c. More specifically, formed with the diaphragm 100 inthe closed position is a first fluid supply or inlet sub-chamber 24 a incommunication with the inlet 14, a second fluid supply or outletsub-chamber 24 b in communication with the outlet 16 and a diaphragmsub-chamber 24 c. The cover portion 12 a preferably includes a centralopening 13 for introducing an equalizing fluid into the diaphragmsub-chamber 24 c. By equalizing the pressure between sub-chamber 24 cand sub-chambers 24 a and 24 b, the tension within the diaphragm 100(e.g., in layer 103, which is, for example, a reinforced fabric) urgesthe flexible member 100 a to the lower position. In some embodiments,the inversion inhibitor 35, which is described below, creates a tensionforce within the flexible member 100 a that aids in urging the flexiblemember 100 a to the lower position. Once the diaphragm 100 makes contactwith the seat member 26, the pressures are no longer equalized on eachside of the flexible member 100 a, and the corresponding difference inthe forces holds the diaphragm 100 against seat member 26.

As seen in FIG. 2, the preferred diaphragm member 100 is configured toengage and cooperate with the inner surfaces of the cover portion 12 aand body portion 12 b to define the three sub-chambers 24 a, 24 b, 24 cin an orientation that can provide for a diaphragm sub-chamber 24 c thatcan effectively compensate for fluctuations and/or surges in fluidpressure in either one of the inlet and outlet sub-chambers 24 a, 24 b.Preferably, the equalizing fluid is provided from the first fluid sourcesuch that any surges in flow or pressure experienced at the inletsub-chamber 24 a is also experienced in the diaphragm sub-chamber 24 c.In this manner, the diaphragm sub-chamber 24 c can react and compensatewith a diaphragm pressure to maintain the flexible member 100 a in thelower position.

The material to be used for manufacturing the diaphragm 100 is dependenton the type of fluid being carried and on the temperature range to whichthe diaphragm is to be exposed. Preferably, the upper and lower layers102, 104, respectively of the diaphragm 100 are constructed from layersof elastomeric material having a durometer hardness or shore value ofabout 55 to 75, and preferably about 60 to 70, and a minimum tensilestrength of about 1700 pounds per square inch (psi.) (11.721 MPa).Suitable materials for use at the upper and lower layers 102, 104include, for example, natural rubber, nitrile butadiene rubber,neoprene, ethylene propylene diene monomer (EPDM), or anotherappropriate elastomer. Materials that can be used for reinforcementsbetween the upper and lower surface layers at middle layer 103 of thediaphragm 100 include a fabric made of, for example, cotton, polyester,and nylon and more preferably, nylon no. 2 reinforced material. Thus, inpreferred embodiments, the diaphragm 100 includes a reinforced fabricembedded in a rubber matrix. When the diaphragm 100 is in the invertedposition, the tension force is concentrated in the reinforced fabric.Preferably, two layers of reinforced fabrics are disposed at a 45 degreeangle to each other with respect to a weave pattern of reinforcedfabrics. By arranging the reinforced fabrics at 45 degrees to eachother, the stresses on the diaphragm 100 (due to the pressure on thelower surface 104 a of the flexible member 100 a) are evenlydistributed.

In operation, the equalizing fluid can be relieved from the diaphragmsub-chamber 24 c in preferably a controlled manner to urge the diaphragmmember 100 to the open or actuated position, in which the diaphragmmember 100 is inverted and spaced from the seat member 26 therebypermitting the flow of fluid between the inlet 14 and the outlet 16.Preferably, the diaphragm 100 conforms to at least a portion of theinner surface 17 of the cover portion 12 a. In some embodiments, thediaphragm 100 conforms to substantially the entire inner surface 17 ofthe cover portion 12 a. The fluid release from the diaphragm sub-chamber24 c can be regulated by way of, for example, an electrically controlledsolenoid valve, such that the diaphragm member 100 can achieve regulatedpositions between the fully closed position and the fully open position.Accordingly, the diaphragm member 100 is preferably electricallyactuated between the open and closed positions. Alternatively, thediaphragm can be actuated, regulated and/or closed or latched by othermechanisms such as, for example, a mechanical latching mechanism.

FIG. 3 illustrates a perspective view of the diaphragm 100. As discussedabove, the diaphragm 100 includes a flexible member 100 a, a lip member100 b and a tab 100 c. Preferably, the upper surface 102 a of theflexible member 100 a is a substantially smooth wall portion 101 havinga constant radius of curvature. For example, the upper surface 102 a canbe a semi-spherical bowl. Preferably, the wall portion 101 of flexiblemember 100 a, is elastic enough to conform to the profile of the innersurface 17 of the cover portion 12 a (see FIG. 2A). Preferably, theflexible member 100 a conforms to at least a portion of the innersurface 17 of the cover portion 12 a. In some embodiments, the flexiblemember 100 a conforms to substantially the entire inner surface 17 ofthe cover portion 12 a. In some embodiments, the substantially smoothwall portion 101 extends to the bottom center of the upper surface 102a. However, in other exemplary embodiments, e.g., as illustrated in FIG.3, the substantially smooth wall portion 101 extends part way andcircumscribes a central portion 105. As best seen in FIGS. 3C and 3F,preferably, a thickness of the central portion 105 increases in a radialdirection from the substantially smooth wall portion 101 to the centerof flexible member 101 a such that the upper surface 102 a issubstantially flat along the central portion 105. Preferably, atransition portion 105 a provides a tapered transition from thesubstantially smooth wall portion 101 to the central portion 105.Although thicker than the substantially smooth wall portion 101, thecentral portion 105 is still elastic enough to conform to at least aportion of the inner surface 17 of cover portion 12 a when the diaphragm100 is in the inverted position. Thus, when the flexible member 100 a isforced into the inverted position, the upper surface 102 a of theflexible member 100 a conforms to the profile of the inner surface 17 ofthe cover portion 12 a. Preferably, the flexible member 100 a conformsto substantially the entirety of the inner surface 17, which providessupport for the flexible member 100 a. In contrast, known diaphragms donot conform to the inner surface of the cover. Thus, known diaphragmsmust be made to withstand the full force of the fluid flow and pressurein the valve, which creates stress concentrations in the diaphragm. Inexemplary embodiments, the cover portion 12 a provides support to theflexible member 100 a and thus the flexible member 100 a does not havethe stress concentrations experienced by known diaphragms. This meansthat exemplary embodiments of the diaphragm 100 of the presentdisclosure can be more flexible than known diaphragms. In prior art andrelated art valves, any internal tension force within known diaphragms,by itself, is not enough to urge the diaphragm to the lower position dueto its rigidity. However, by making the diaphragm more flexible, thetension force within the diaphragm 100 is enough to urge the diaphragm100 back to the seat member 26 without requiring an additional biasforce from elements and devices such as, e.g., ribs, rings and springs.In addition, by conforming to the inner surface 17 of the cover portion12 a, the flexible member 100 a maximizes the cross-sectional area ofthe passageway between the inlet 14 and the outlet 16. Thus, the controlvalves can be made smaller as compared to similarly rated prior art andrelated art valves.

FIGS. 3A-3F show additional features of the illustrative embodiment ofthe diaphragm 100. The diaphragm 100 includes an upper surface 102 a anda lower surface 104 a. Each of the upper and lower surface areas 102 a,104 a are generally sufficient in size to seal off communication of theinlet and outlet sub-chamber 24 a, 24 b from the diaphragm sub-chamber24 c (see FIG. 2). The geometries of the upper and lower surface areas102 a, 104 a are such that the surfaces effectively dissect and seal thechamber 24. Preferably, as seen in the plan views of FIGS. 3A and 3B,the upper and lower surface areas 102 a, 104 a are preferablysubstantially circular.

The lower surface 104 a of the flexible member 100 a preferably presentsa substantially convex surface, and more preferably a spherical convexsurface having an area AA1, and the upper surface 102 a of the flexiblemember 100 a presents a substantially concave surface, and morepreferably a spherically concave surface having an area AA2. Uppersurface AA2 is preferably about equal to AA1. Portions of the lowersurface 104 a act to seal off fluid communication from the otherchambers, i.e. a portion of lower surface 104 a seals the inletsub-chamber 24 a from the outlet sub-chamber 24 b. The preferredgeometry of the sub-chambers 24 a, 24 b, 24 c relative to one anotherpreferably provides that the areas sealing the inlet and outletsub-chambers 24 a, 24 b are about equal, and that the inlet sub-chamber24 a is sealed off by a portion of the lower surface 104 a having anarea of about ½ AA1, and the outlet chamber is sealed off by a portionof the lower surface 104 a having an area of about ½ AA1. In onepreferred embodiment of the diaphragm 100, the upper surface 102 adefines a radius of curvature r₁ and the lower surface 104 a defines aradius of curvature r₂. Preferably, a ratio of the radii of curvaturesbetween the lower surface 104 a r₂ and the upper surface 102 a r₁(r₂/r₁) is in a range of 1.05 to 1.15. Where the diaphragm 100 includesa middle layer 103, the middle layer 103 can further define a thirdradius of curvature r₃, which is between r₁ and r₂. The various radii ofcurvatures can be measured from a common central point. The ratio of theradius of curvature of a lower surface 104 a to the radius of curvatureof an upper surface 102 a is preferably sufficient to permit the lowersurface 104 a to engage the seat member 26 of bridge element 27 when thediaphragm 100 is in the lower position and adequately seal off the inletand outlet sub-chambers 24 a, 24 b. Preferably, a thickness of theflexible member 100 a can be in a range of 0.30 inch (7.62 mm) to 1.0inch (25.4 mm) and, more preferably, in a range of 0.40 inch (10.16 mm)to 0.80 inch (20.32 mm).

Preferably, the radius of curvature r₂ of the lower surface 104 a and aradius of curvature r₅ of the seat member 26 of the bridge element 27(see FIG. 4C) are corresponding radius of curvatures such that theflexible member 100 a conforms to and seals against the elongated seatmember 26 when the flexible member 100 a is in the non-inverted position(lower position). Preferably, the lower surface 104 a of the flexiblemember 100 a further includes at least one elongated sealing member orprojection 114 to aid in forming a sealed engagement between flexiblemember 100 a and the seat member 26 of the bridge element 27.Preferably, as shown in FIG. 3B, the diaphragm 100 includes a pair ofelongated sealing members or projections 114 a, 114 b. Each of theelongated sealing members 114 a, 114 b further aids in forming thesealed engagement between flexible member 100 a and the seat member 26of the bridge element 27. The sealing members 114 a, 114 b preferablyextend in a parallel fashion along the lower surface 104 a for a lengthabout equivalent to the maximum arc length defined by the surface 104 a.The elongated sealing members 114 a, 114 b each have a geometric profilethat provides a sealing function and can have a profile such as, e.g., asemicircular cross-sectional profile, a semi-ellipse cross-sectionalprofile, a semi-oval shape cross-sectional profile, or any othercross-sectional profile that provides the sealing function discussedherein. Preferably, as seen in FIG. 3E, each of the elongated sealingmembers 114 a, 114 b preferably defines a protruding cross-sectionalarea having a radius of curvature r₄ in a range of about 0.05 inch (1.27mm) to 0.20 inch (5.08 mm) with tangents of the sidewalls at theinterface to the lower surface 104 a forming an angle θ in a range of 55degrees 65 degrees. A height h of the elongated sealing members 14 a,114 b is in a range of 0.04 inch (1.016 mm) to 0.12 inch (3.048 mm).

As seen in FIG. 3C, the sealing members 114 a, 114 b are preferablyspaced apart so as to define a void or channel 118 therebetween. Thesealing members 114 a, 114 b along with a portion of the lower surface104 a disposed therebetween further define the sidewalls of the void orchannel 118 and its channel height. The sealing members 114 a, 114 b areconfigured to engage the seat member 26 of the bridge element 27 whenthe diaphragm is in the closed position so as to seal off communicationbetween the inlet 14 and the outlet 16 and more specifically seal offcommunication between the inlet sub-chamber 24 a and the outletsub-chamber 24 b. Preferably, in some embodiments, the sealing members114 a, 114 b engage the seat member such that the channel 118 cooperateswith the seat member 26 to form an intermediate chamber 24 d to axiallyspace the inlet sub-chamber 24 a and the outlet sub-chamber 24 b in amanner described in greater detail herein below. Although the exemplaryembodiment is described with two sealing members, 114 a, 114 b, thelower surface 104 a of the diaphragm 100 can include just one sealingelement or more than two sealing elements provided that each sealingelement cooperates with the seat member 26 in a sealing fashion.

FIG. 4 shows a perspective view of the body portion 12 b. The innersurface 19 of the body portion 12 b includes a bridge element 27. Thebridge element 27 includes a valve seat member 26. As seen in FIG. 4A,the body portion 12 b preferably defines a valve axis IVB-IVB. The inletand outlet 14, 16 of the control valve 10 are preferably centered about,coaxial with and spaced apart along the valve axis IVB-IVB. The bodyportion 12 b further preferably defines an axis IVC-IVC which issubstantially orthogonal to the axis IVB-NB. Preferably aligned with theaxis IVC-IVC is the bridge element 27 extending the width of the bodyportion 12 b so as to effectively divide the chamber 24 in the bodyportion 12 b into the preferably spaced apart and preferably equal sizedsub-chambers, e.g., the inlet sub-chamber 24 a and the outletsub-chamber 24 b. The body portion 12 b also includes one or moresupport members 28 a,b that are respectively connected to each side ofthe bridge element 27. The support members 28 a,b preferably extend fromthe flanges of the inlet and outlet 14, 16 to intersect the bridgeelement 27. The support members 28 a,b are disposed in a direction thatis substantially parallel to the first axis IVB-IVB, i.e., perpendicularto the bridge element 27. Preferably, each side of the bridge element 27can have a plurality of support members 28 a,b, with the number ofsupport members 28 a,b being based on the size of the valve 10 and/orthe pressure rating of the valve 10. Preferably, the bridge element 27has 3 to 21 support member 28 a,b, more preferably 3 to 11 supportmember 28 a,b, and even more preferably 5 to 9 support members 28 a,b.In the exemplary embodiment of FIG. 4A, there are five support members28 a,b on the respective sides of bridge element 27. Of course,exemplary embodiments can have fewer than three or more than elevendepending on design criteria such as pressure drop across the valve 10.In addition, the number of support members 28 a,b on each side need notbe the same. For example, the body portion 12 b can have five supportmembers 28 b and only three support members 28 a or some othercombination depending on the needs of the system. The support members 28a,b preferably form a unitary construction with the bridge element 27and the rest of the body portion 12 b, or alternatively, the supportmembers 28 a,b can be joined to the bridge element 27 and the bodyportion 12 b by other joining techniques such as, for example, welding.

The surface of the seat member 26 of bridge element 27 preferablydefines an arc having an arc length to mirror the convex surface of thelower surface 104 a of the diaphragm 100. For example, the radius r₅(see FIG. 4C) and the radius r₂ (see FIG. 3C) are corresponding radiusof curvatures. In addition, the arc length corresponding to the surfaceof seat member 26 is substantially equal to the arc length correspondingto the lower surface 104 a of flexible member 100 a. Further, thesurface of each of the support members 28 a,b preferably defines an arcthat mirrors the convex surface of the lower surface 104 a of theflexible member 100 a. For example, the radius r₆ (see FIG. 4B)corresponding to the surface of each support member 28 and the radius r₂(see FIG. 3C) corresponding to the lower surface 104 a of flexiblemember 100 a are corresponding radius of curvatures. By having the radiir₆, r₅ substantially match the radius r₂, the spherical surface profileof the combined structure of the support members 28 a,b and bridgeelement 27 substantially matches the profile of the lower surface 104 a.Thus, the load from the lower surface 104 a when the diaphragm 100 is inthe lower position will be spread substantially evenly over an areaformed by the surfaces of support members 28 a, b and the surface ofbridge element 27. By spreading the load, the stress concentrations inthe flexible member 100 a are minimized when the flexible member 100 ais in the closed position. In some prior art and related art systems,support members do not exist or are offset from the valve seat such thatthe support members and the valve seat are not on the same sphericalsurface. This means that the diaphragm must be designed to handle theload created by the pressure chamber with little or no support fromadditional valve structures. This leads to a more rigid diaphragmconstruction and the associated problems discussed above. In exemplaryembodiments of the present disclosure, the support members 28 a,b andbridge element 27 provide support such that the flexible member 100 acan be more elastic. As discussed above, a more elastic flexible member100 a allows for a diaphragm configuration in which basing elements suchas ribs and springs can be eliminated.

Preferably, in some embodiments, extending along the preferred arclength of the bridge element 27 is a groove or channel 30 constructed orformed in the surface of the seat member 26. The groove 30 preferablyextends the full length of the seat member 26 so as to extend the widthof the body portion 12 b. Furthermore, the groove 30 preferably tapersnarrowly at its ends. In addition, the walls of the seat member 26 thatdefine the groove 30 are preferably parallel. Alternatively, the groove30 can be formed such that the walls forming the groove 30 are angledrelative to one another, another reference line or other surface in thevalve body 12. The bottom of the groove 30 preferably forms asemi-circular arc in the plane perpendicular to the direction ofelongation for the groove 30. Other geometries are possible provided thechannel 30 delivers the desired fluid and hydraulic characteristics forthe appropriate exemplary embodiments as described herein. Moreover, thedepth of the groove 30 can vary along its length such that the groove 30is preferably deepest at its center and becomes more shallow toward itslateral ends. The groove 30 further bisects the engagement surface ofthe seat member 26 preferably evenly along the seat member length. Whenthe diaphragm member 100 is in the closed positioned, the elongatedsealing members 114 a, 114 b are preferably aligned to engage thebisected surface of the seat members 26. Preferably, engagement of thesealing members 114 a, 114 b with the engagement surfaces 26 a, 26 b ofthe seat member 26 further places the channel 118 of the diaphragm 100in communication with the groove 30.

As seen in FIG. 4A, preferably, the engagement surfaces 26 a, 26 b ofthe seat member 26 are substantially planar. Generally, the surfaces 26a, 26 b are configured sufficiently wide over their entire length so asto maintain sealing contact with the lower surface 104 a of flexiblemember 100 a. Preferably, the surfaces 26 a, 26 b are configured wideenough so as to maintain sealing contact with sealing members 114 a, 114b regardless of any movement of the sealing members 114 a, 114 b alongthe longitudinal axis IVB-IVB. Accordingly, the surfaces 26 a, 26 b canmaintain sealed engagement with the lower surface 104 a, whichpreferably includes sealing members 114 a, 114 b, despite changes influid pressure in either the inlet or outlet sub-chamber 24 a, 24 bwhich can impose forces on the flexible member 100 a and sealing members114 a, 114 b in a direction along the axis IVB-IVB.

As seen in FIG. 4B, the bridge element 27 is preferably formed with acentral base member 32 that further separates and preferably spaces theinlet and outlet sub-chambers 24 a, 24 b and diverts fluid in adirection between the diaphragm 100 and the seat member engagementsurfaces 26 a, 26 b. As seen, for example, in FIGS. 4B and 4C, the basemember 32 is preferably broader in the direction along the axis IVB-IVBthan along the axis IVC-IVC. The base member 32 is preferablysubstantially aligned with the central axis B-B of the valve body 12which intersects substantially orthogonally the plane formed by theintersection of the axis IVB-IVB and the axis IVC-IVC. In someembodiments, a port 22 is formed in the base member 32 between inletsub-chamber 24 a and outlet sub-chamber 24 b. The drain 18 diverts thefirst fluid, water from a water main, entering the valve 10 through theinlet 14 to outside the valve bodyl2. The input opening 20 can be usedto introduce the second fluid, e.g., compressed gas, into the valve body12 for discharge out the outlet 16.

The port 22 is preferably constructed as an alarm port from one or morevoids formed in the base member 32. The port 22 preferably extendssubstantially perpendicular to a central axis B-B so as to intersect andbe in communication with a channel that extends to the groove 30. Afterthe port 22 is constructed, the channel can be plugged using plug 50.Accordingly, when the diaphragm member 100 is in the closed position,the port 22 is further preferably in sealed communication with thechannel 118 formed in the diaphragm member 100. Alternatively or inaddition to the port 22, in some embodiments, the plug 50 can be removedand the channel can be used as an alarm port.

The communication between the diaphragm channel 118, the groove 30 andthe port 22 is preferably bound by the sealed engagement of the sealingmembers 114 a, 114 b with the seat member surfaces 26 a, 26 b, tothereby define a preferred fourth chamber, intermediate chamber 24 d, asseen, for example, in FIG. 2. The intermediate chamber 24 d ispreferably open to atmosphere thereby further defining a fluid seat,preferably an air seat, to separate the inlet and outlet sub-chambers 24a, 24 b. Providing an air seat between the inlet and outlet sub-chambers24 a, 24 b allows each of the inlet and outlet chambers to be filled andpressurized while avoiding failure of the sealed engagement between thesealing member 114 and the seat member 26. Because each sealing member114 is acted upon by a fluid force on only one side of the element andpreferably atmospheric pressure on the other, the fluid pressure in thediaphragm sub-chamber 24 c is effective to maintain the sealedengagement between the sealing member 114 and the seat member 26 duringpressurization of the inlet and outlet sub-chambers 24 a, 24 b.

FIG. 5 is a perspective view of the cover portion 12 a. The coverportion 12 a includes a dome section 21 and a flange section 23.Preferably, the flange section 23 includes a plurality of bolt holes 25to receive bolts 29 or threaded studs 29 a (see FIG. 1). The threadedstuds 29 a facilitate the assembly of the cover portion 12 a when thevalve 10 is mounted in a vertical position. For example, the coverportion 12 a can be hung on the threaded studs 29 a while the bolts 29are inserted in the remainder of the holes 25. The cover portion 12 aand the body portion 12 b are preferably coupled together by a pluralityof bolts distributed in a bolt pattern about the body 12. A preferredbolt pattern includes eight bolt/nut assemblies. In an alternative boltassembly, a threaded stud assembly or a combination of both bolts andthreaded studs can be utilized. Preferably, the bolt or threaded studpattern is disposed on the valve body 12 such that the bolts do notpenetrate diaphragm 100. That is, the bolts and/or threaded studs aredisposed outside the outer perimeter of diaphragm 100 as seen in FIG.2B.

As seen in FIG. 5A, an inside surface 17 of the cover portion 12 a has adome-shaped profile that permits the flexible member 100 a to conform tothe inside surface 17. Preferably, the dome-shaped profile has a radiusr₇ with respect to a point on the centerline of the cover portion 12 a.Preferably, the dome-shaped profile extends to the edge 31 (see dottedline in FIG. 5A) of the cover portion 12 a at the interface to thediaphragm 100. By extending the dome-shaped profile to the edge 31, thecover portion 12 a does not prevent the flexible member 100 a from fullyinverting, e.g., does not prevent the flexible member 100 a fromreaching its natural-inverted position.

However, in some embodiments, as seen in FIG. 5A, the dome-shapedprofile is limited to a central section 33 of the cover portion 12 a andan inversion inhibitor 35 extends from the cover portion 12 a, near theedge 31. The inversion inhibitor 35 prevents the flexible member 100 afrom reaching its natural-inverted position by blocking the flexiblemember 100 a. Although the flexible member 100 a can conform to theinner surface 17 of the cover portion 12 a, including the inversioninhibitor 35, the flexible member 100 a does not fully invert (e.g.,does not reach its natural-inverted position) as in a case where thecover portion 12 a does not include an inversion inhibitor 35. Byblocking the full inversion of the flexible member 100 a, the inversioninhibitor 35 creates a tension force within the flexible member 100 athat urges the flexible member 100 a to the seat member 26.

As seen in FIG. 5A, when compared to the surface profile of centralsection 33, the surface profile of the inversion inhibitor 35, whichcircumscribes the central section 33, projects into the chamber 24toward the central axis of the cover portion 12 a. The projection intothe chamber 24 by the inversion inhibitor 35 blocks the full inversionof the flexible member 100 a. The inversion inhibitor 35 can be, forexample, a bulge or protruding section on the inner surface of thechamber 24. Preferably, as shown in FIG. 5A, the inversion inhibitor 35is a deviation of the inner surface 17 from a surface curvature definedby radius r₇ (see deviation from dotted line in FIG. 5A). Preferably,deviation of the inner surface 17 is greatest near the edge 31 adjacentto the diaphragm 100 when the control valve 10 is assembled and thedeviation gradually decreases to zero, i.e., the inner surface profilematches the surface profile corresponding to the radius r₇, in adirection towards the central section 33. Preferably, a maximumthickness t″ of the inversion inhibitor 35, as measured in a radialdirection from the surface of the inversion inhibitor 35 towards asurface corresponding to radius r₇, is in a range of 0.10 inch (2.54 mm)to 0.70 inch (17.78 mm). Preferably, the inversion inhibitor 35 has alength L that is in a range of 0.5 inch (12.7 mm) to 4.5 inch (114.3 mm)as projected on a plane that is perpendicular to the radius r₇ at themaximum thickness t″ of the inversion inhibitor 35.

In some embodiments, the inversion inhibitor 35 defines a substantiallyrounded cross-sectional profile. For example, the cross-sectionalprofile can be a substantially semicircular profile, substantially asemielliptical profile with respect to a major axis or a minor axis, asubstantially triangular-shaped profile, or any other profile that canprovide a bias force on the flexible member 100 a to urge or aid inurging the flexible member 100 a to the seat member 26. Preferably, asseen in FIG. 5A, the inversion inhibitor 35 at edge 31 adjacent to thediaphragm 100 is curved such that the cross-sectional profile issubstantially a semi-tear drop shaped profile. In the direction from thecentral section 33 to the edge 31, the tear-drop profile provides for agradual increase in the deviation of the inner surface 17 from the linecorresponding to radius r₇. By gradually increasing the deviation, theflexible member 100 a can still conform to the inner surface 17 of coverportion 12 a when the flexible member 100 a is in the inverted position.In some embodiments, along with the tension force in the layer 103 ofdiaphragm 100, the inversion inhibitor 35 can create a tension forcewithin the flexible member 100 a to aid in urging the flexible member100 a to the seat member 26 as discussed above.

As discussed above, lip element 100 b of diaphragm 100 circumscribes theflexible member 100 a. As seen in FIGS. 4D and 5B, preferably, the coverportion 12 a and the body portion 12 b each include a channel 36, 37,respectively, that circumscribes the chamber 24. When the cover portion12 a and the body portion 12 b are joined together, the channels 36 and37 define a cavity 39 (see FIG. 2) for receiving the lip member 100 b.Each channel 36, 37 includes an outer radial wall 36 a, 37 a,respectively, and an inner radial wall 36 b, 37 b, respectively. Theinner radials walls 36 b, 37 b are shorter in length than the outerradial walls 36 a, 37 a, respectively, such that when assembled, a gapis formed that provides a passage from the cavity 39 to the chamber 24.In the embodiments of FIGS. 4D and 5B, the channels 36 and 37 haveprofiles that are substantially square but with the inner radial walls36 b and 37 b disposed at a slight angle with respect to a normal to thechannel base 36 c, 37 c. In other embodiments, for example, as seen inFIGS. 4E and 5C, the channels 36′ and 37′ have profiles that aresubstantially trapezoidal in shape with both the outer radial walls 36a′, 37 a′ and the inner radial walls 36 b′, 37 b′ are at an angle withrespect to a normal to the channel base 36 c′, 37 c′. The shape anddimensions of the channels will depend on the pressure rating of thevalve 10 and/or the geometry of the valve 10. For example, the channelshape and dimension can be configured to limit any obstruction to theinlet 14 and outlet 16 of valve 10. Preferably, the shapes anddimensions of the corresponding channels between the cover portion 12 aand the body portion 12 b are substantially the same, for example, asseen in FIGS. 4D and 5B. However, in some embodiments the shapes anddimensions can be different. For example, as seen in FIGS. 4E and 5C,the base of channel 36 c′ is narrower than the base of channel 37 c′.

The diaphragm 100 is disposed between the cover portion 12 a and thebody portion 12 b. When the control valve 10 is assembled, the cavity 39engages the lip member 100 b of the diaphragm 100 such that the channel36 of cover portion 12 a and the channel 37 of the body portion 12 bpinch the lip member 100 b to securely hold the diaphragm 100. Becausethe lip member 100 b is secured, when the flexible member 100 a isinverted as discussed above, a tension force is created in layer 103 ofthe diaphragm 100.

In preferred embodiments, the diameter of the circle defining cavity 39is smaller than the diameter of the circle defining the bolt pattern forbolts 29 and/or threaded studs 29 a. In this way, the bolts 29 and/orthreaded studs 29 a are disposed on the valve body 12 such that thebolts/threaded studs do not penetrate diaphragm 100. That is, the boltsand/or threaded studs are disposed outside the outer perimeter of lipmember 100 b of diaphragm 100 as seen in FIG. 2B. By disposing thebolts/threaded studs outside the circumference of diaphragm 100, thediaphragm 100 in preferred embodiments does not have any holes and thusdoes not experience the high stress concentrations that known diaphragms(in which the bolts go through the diaphragm) experience around theholes during the open/close cycles of the valve.

Preferably, the lip element 100 b forms a seal between the chamber 24and the outside atmosphere that can withstand the operating pressure ofthe control valve 10 when the valve 10 is assembled and in operation.The cross-sectional profile of the lip element 100 b can be asemicircle-shaped cross-section, an elliptical-shaped cross-section orany other cross-sectional profile so long as the lip member 100 bprovides the requisite seal. For example, FIGS. 3C and 3D illustrate apreferred configuration of the lip member 100 b. The lip member 100 b isreceived by the cavity 39. The lip member 100 b preferably has asubstantially oval-shaped cross-section 43. Preferably, the oval-shapedcross-section 43 has a flattened profile on a side adjacent to theflexible member 100 a. The oval-shaped cross-section 43 includes twoendpoints 41 a, 41 b that respectively engage the upper surface 17 ofthe cover portion 12 a in channel 36 and the lower surface 19 of thebody portion 12 b in channel 37. Preferably, the thickness t of the lipmember 100 b is in a range of 0.60 inch (15.24 mm) to 1.2 inches (30.48mm), and more preferably 0.9 inch (22.86 mm) to 1.1 inches (27.94 mm).When secured, the two endpoints, which are composed of a rubber orelastic material, are pinched in the cavity 39 and deformed so as toseal the control valve 10.

In another exemplary embodiment, for example, as seen in FIG. 3G, apreferred configuration of the lip member 100 b′ has substantially arectangular-shaped cross-section 43′. Preferably, the rectangular-shapedcross-section 43′ includes two ends 41 a′, 41 b′ that respectivelyengage the upper surface 17 of the cover portion 12 a of channel 36′ andthe lower surface 19 of the body portion 12 b of channel 37′.Preferably, the thickness t′ of the lip member 100 b′ is in a range of0.60 inch (15.24 mm) to 1.2 inches (30.48 mm), and more preferably 0.9inch (22.86 mm) to 1.1 inches (27.94 mm). When secured, the two ends,which are composed of a rubber or elastic material, are pinched in thecavity formed by channels 36′, 37′ and deformed so as to seal thecontrol valve 10.

Preferably, the lip member 100 b, 100 b′ is composed of a material thatis not compressible. Preferably, the lip member 100 b,100 b′ has thesame material composition as the rest of diaphragm 100. By disposing thelip member 100 b, 100 b′ between two channels 36, 37 or 36′, 37′ inpreferred embodiments as discussed above, minor flaws and imperfectionsin the flanges or the diaphragm will not prevent the lip member 100 b,100 b′ from sealing the valve 10.

As seen in FIGS. 3D and 3G a transition portion from the respective lipmembers 100 b, 100 b′ to the flexible member 100 a includes an uppercurvilinear path 45 corresponding to the upper surface 102 a and a lowercurvilinear path 47 corresponding to the lower surface 104 a. Thetransition portion is disposed in the gap between the respective innerradial walls, i.e., 36 b and 37 b or 36 b′ and 37 b′. Preferably, theupper curvilinear path 45 has a tighter curved path than the lowercurvilinear path 47. The upper and lower curvilinear paths 45, 47preferably transition to the flexible member 100 a at substantially amid-point of the side of the respective lip member 100 b, 100 b′.

Turning to FIG. 6, the control valve 10 can be placed into service bypreferably bringing the valve 10 to the normally closed position andsubsequently bringing the inlet sub-chamber 24 a and the outletsub-chamber 24 b to operating pressure. In one preferred installation,the first fluid source is initially isolated from the inlet sub-chamber24 a by way of a shut-off control valve such as, for example, a manualcontrol valve located upstream from the inlet 14. The second fluidsource is preferably initially isolated from the outlet sub-chamber 24 bby way of a shut-off control valve located upstream from the inputopening 20. If the pressures in sub-chambers 24 a and 24 c are alreadyequalized at this point, e.g. the pressures P1, P2, P3 are equal, thetension force within the diaphragm 100 and, in some embodiments, aidedby the additional tension force created by the inversion inhibitor 35,will urge the flexible member 100 a from the inverted position to theclosed position as discussed above. If not, for example P2 and P3 aregreater than P1, the following steps will place the control valve 10 ina state ready for operation. An equalizing fluid, such as water from thefirst fluid source is then preferably introduced into the diaphragmsub-chamber 24 c through the central opening 13 in the cover portion 12a. Fluid is continuously introduced into the sub-chamber 24 c until thefluid exerts enough pressure P1 to bring the flexible member 100 a tothe closed position in which the lower surface 104 a engages the bridgeelement 27. In the closed position, the lower surface 104 a of flexiblemember 100 a, which in some embodiments includes the sealing members 114a, 114 b, forms a sealed engagement about the seat member 26.

With the diaphragm member 100 in the closed position, the inlet andoutlet sub-chambers 24 a, 24 b can be pressurized respectively by thefirst and second fluids. More specifically, the shut-off valve isolatingthe first fluid, e.g., water from a water main, can be opened so as tointroduce the first fluid through the inlet 14 and into the inletsub-chamber 24 a to preferably achieve a static pressure P2. Theshut-off valve isolating the second fluid, e.g., the compressed gas, canbe opened to introduce the second fluid through the input opening 20 topressurize the outlet sub-chamber 24 b and the normally closed system,e.g., a fire system piping network, coupled to the outlet 16 of thecontrol valve 10 to achieve a static pressure P3.

As described above, the intermediate chamber 24 d is disposed betweenthe inlet and outlet sub-chambers 24 a, 24 b and is normally open toatmosphere. The primary fluid pressure P2 is isolated from chamber 24 dby the sealing member 114 a and the secondary fluid pressure P3 isisolated from chamber 24 d by the sealing member 114 b. Thus, diaphragmmember 100, and in some embodiments its sealing members 114 a, 114 b, isconfigured so as to maintain the sealed engagement with the seat member26 under the influence of the diaphragm chamber pressure P1.Accordingly, when in the closed position, the upper and lower diaphragmsurface areas A1, A2, and A3 are preferably sized such that the forceprovided by pressure P1 is large enough to overcome the forces providedby primary and secondary fluid pressures P2, P3 urging the diaphragmmember 100 to the open position. However, the upper and lower diaphragmsurface areas A1, A2, and A3 are also sized to provide a fast openingresponse. Because the flexible member 100 a is not as rigid as prior artand related art diaphragms, the valve 10 has a faster opening responsethan such diaphragms when fluid is released from the inlet chamber. Inaddition, the pressure drop due to the diaphragm and/or biasing devicessuch as ribs and springs is also minimized.

To actuate the valve 10, fluid is preferably released from the diaphragmsub-chamber 24 c at a faster rate than it can be replenished into thesub-chamber 24 c. For example, a solenoid control valve coupled to thechamber inlet 13 can be electrically actuated to release fluid from thediaphragm sub-chamber 24 c. The loss of pressure on the upper surface102 a of the diaphragm member 100 permits the fluid pressure in theadjacent fluid supply sub-chamber 24 a to urge the diaphragm member tothe open position spaced from the seat member 26. Fluid is permitted toflow past the support members 28 a, 28 b to displace the compressed gasin the outlet sub-chamber 24 b for discharge out the outlet 16 and intothe system coupled to the control valve 10. Fluid is further permittedto fill the groove 30 and flow out the alarm port 22. With anappropriate flow alarm coupled to the port 22, fluid flow can bedetected and appropriate personnel can be notified of the operation ofthe valve 10. Accordingly, the control valve 10 can be installed in apreaction fire protection systems with its outlet 16 in communicationwith a riser pipe that is coupled to a network of sprinklersinterconnected by pipes and pressurized by the compressed gas or air.

While the present invention has been disclosed with reference to certainembodiments, numerous modifications, alterations, and changes to thedescribed embodiments are possible without departing from the sphere andscope of the present invention, as defined in the appended claims.Accordingly, it is intended that the present invention not be limited tothe described embodiments, but that it has the full scope defined by thelanguage of the following claims, and equivalents thereof.

What is claimed is:
 1. A fluid control valve comprising: a cover portionwith a first inner surface and a first channel; a body portion securedto the cover portion, the body portion having a second inner surface anda second channel, the first and second inner surfaces defining achamber; and a diaphragm disposed between the cover portion and the bodyportion, the diaphragm including a flexible member disposed in thechamber and a lip member circumscribing the flexible member, wherein thefirst channel and the second channel define a cavity that circumscribesthe chamber and the cavity is configured such that each channel receivesa portion of the lip member and pinches the lip member to seal the fluidcontrol valve and hold the diaphragm.
 2. The fluid control valve ofclaim 1, wherein the cover portion is secured to the body portion usinga plurality of at least one of bolts and threaded studs, and wherein theplurality of at least one of bolts and threaded studs are disposedoutside an outer perimeter of the diaphragm.
 3. The fluid control valveof any one of claims 1 and 2, wherein a tension force within theflexible member is created when the flexible member is inverted and thelip member is held between the cover portion and the body portion. 4.The fluid control valve of claim 3, wherein the diaphragm includes areinforced fabric embedded in a rubber matrix, and wherein the tensionforce is concentrated in the reinforced fabric when the flexible memberis inverted.
 5. The fluid control valve of claim 4, wherein thereinforced fabric includes a first fabric member that is disposed at a45 degree angle to a second fabric member with respect to a weavepattern of the first and second fabric members.
 6. The fluid controlvalve of any one of claims 1 to 5, wherein a thickness of the lip memberis in a range of 0.60 inch (15.24 mm) to 1.2 inches (30.48 mm).
 7. Thefluid control valve of any one of claims 1 to 6, wherein a transitionportion from the lip member to the flexible member includes an uppercurvilinear path corresponding to an upper surface of the flexiblemember and a lower curvilinear path corresponding to a lower surface ofthe flexible member.
 8. The fluid control valve of claim 7, wherein theupper curvilinear path has a tighter curved path than the lowercurvilinear path.
 9. The fluid control valve of any one of claims 7 and8, wherein the lip member transitions to the flexible member atsubstantially a mid-point of a side of the lip member.
 10. The fluidcontrol valve of any one of claims 1 to 9, wherein the lip memberdefines a substantially oval-shaped cross-sectional profile.
 11. Thefluid control valve of claim 10, wherein end points of the oval-shapedcross-section with respect to a longitudinal axis of the oval-shapedcross-section are pinched to create the seal.
 12. The fluid controlvalve of claim 10, wherein the oval-shaped cross-section has a flattenedprofile on a side adjacent to the flexible member.
 13. The fluid controlvalve of any one of claims 1 to 12, wherein the lip member defines asubstantially semicircle-shaped cross-sectional profile.
 14. The fluidcontrol valve of any one of claims 1 to 13, wherein a maximum thicknessof the flexible member is in a range of 0.30 inch (7.62 mm) to 1.0 inch(25.4 mm).
 15. The fluid control valve of any one of claims 1 to 14,wherein the body portion includes an elongated seat member substantiallyaligned along a plane perpendicular to a flow axis of the fluid controlvalve, the first and second inner surfaces defining a chamber when thecover portion and the body portion are joined, the chamber including aninlet and an outlet in communication with the chamber, wherein theflexible member has a first position in which the flexible member isinverted to define a passageway to permit communication between theinlet and the outlet and a second position to prevent fluidcommunication between the inlet and the outlet of the fluid controlvalve, and wherein the diaphragm biases the flexible member from thefirst position to the second position so that the flexible memberconforms to and seals against the elongated seat member when theflexible member is in the second position.
 16. The fluid control valveof claim 15, wherein the upper surface of the flexible member has asubstantially smooth wall portion and, when the flexible member isinverted, the upper surface conforms to at least a portion of the firstinner surface of the cover portion.
 17. The fluid control valve of claim16, wherein an entirety of the upper surface of the flexible memberconforms to the first inner surface of the cover portion when theflexible member is inverted.
 18. The fluid control valve of any one ofclaims 15 to 17, wherein a lower surface of the flexible member and theelongated seat member have corresponding radius of curvatures such thatthe flexible member conforms to and seals against the elongated seatmember when the flexible member is in the second position
 19. The fluidcontrol valve of any one of claims 15 to 18, wherein the elongated seatmember is part of a bridge element that bisects the body portion alongthe plane to define a first side and a second side, and wherein the bodyportion further includes one or more first support members disposed onthe first side and one or more second support members disposed on thesecond, the first and second support members being disposed about andengaged with the bridge element.
 20. The fluid control valve of claim19, wherein the first and second support members are disposed in therespective first and second sides in a direction substantially parallelto the flow axis.
 21. The fluid control valve of claim 20, wherein thefirst and second support members are integrally formed with the bridgeelement.
 22. The fluid control valve of claim 20, wherein each surfaceof the first and second support members and the bridge element define anarc that mirrors a convex surface of a lower surface of the flexiblemember such that a load from the lower surface of the flexible member isspread substantially evenly on an area formed by the surfaces of thefirst and second support members and the bridge element.
 23. The fluidcontrol valve of any one of claims 15 to 22, wherein a lower surface ofthe flexible member includes at least one elongated member to aid insealing the flexible member against the elongated seat member.
 24. Thefluid control valve of any one of claims 16 to 23, wherein thesubstantially smooth wall portion defines a substantially semi-sphericalbowl.
 25. The fluid control valve of any one of claims 1 to 24, whereinthe inner surface of a central section of the cover portion has aconcave profile.
 26. The fluid control valve of claim 25, wherein theconcave profile has a constant radius of curvature.
 27. The fluidcontrol valve of any one of claims 16 to 26, wherein the substantiallysmooth wall portion circumscribes a central portion.
 28. The fluidcontrol valve of claim 27, wherein a thickness of the central portionincreases in a radial direction from the substantially smooth wallportion to a center of the central portion such that the upper surfaceis flat along the central portion.
 29. The fluid control valve of claim23, wherein the at least one elongated member has a cross-sectional areathat is one of a semicircle, a semi-ellipse and a semi-oval shape. 30.The fluid control valve of claim 19, wherein the bridge element includesa groove, a portion of the body portion further defining a port incommunication with the groove, and wherein a lower surface of theflexible member includes a pair of elongated members to aid in sealingthe flexible member against the elongated seat member, the pair ofelongated members being spaced apart to define a channel therebetween,the channel in communication with the groove to define an intermediatechamber in communication with the port when the flexible member is inthe second position.
 31. The fluid control valve of claim 30, whereinthe flexible member defines a central axis substantially perpendicularto the flow axis and parallel to the plane, and wherein each of theelongated members defines a sidewall surface of the channel.
 32. Thefluid control valve of any one of claims 30 and 31, wherein theelongated seat member defines a curvilinear surface having an arc lengthfor engaging the lower surface of the flexible member, the grooveextending along the curvilinear surface for substantially the entire arclength.
 33. The fluid control valve of claim 19, wherein the bodyportion includes an input opening and a fluid drain opening disposedabout the bridge element, the input opening being in communication withthe outlet and the fluid drain opening being in communication with theinlet.
 34. The fluid control valve of claim 33, wherein the body portiondefines a central axis substantially perpendicular to the flow axis andparallel to the plane, the port being substantially aligned with thecentral axis.
 35. A method of operating fluid control valve having acover portion with a first channel, a body portion having a secondchannel, and a diaphragm having a flexible member that has an uppersurface and a lower surface and a lip member circumscribing the flexiblemember, the method comprising: pinching the lip member between the firstchannel and the second channel to seal the fluid control valve;inverting the flexible member to conform at least a portion of the uppersurface of the flexible member to the inner surface of the cover portionby removing fluid pressure from the upper side of the flexible member,the inverted position of the flexible member permitting fluidcommunication between an inlet and an outlet of the fluid control valve.36. The method of claim 35, wherein the inverting the flexible membercreates a tension within the diaphragm that biases the flexible membersuch that the flexible member moves to a non-inverted position whenpressures on the upper surface and the lower surface of the flexiblemember are substantially equalized.
 37. The method of claim 36, wherein,when the pressures on the upper surface and the lower surface of theflexible member are substantially equalized, the flexible member sealsagainst the elongated seat member so as to prevent fluid communicationbetween the inlet and the outlet.
 38. The method of any one of claims 36and 37, wherein the tension force is concentrated in a reinforced fabriclayer of the flexible member when the flexible member is inverted. 39.The method of claim 38, wherein the reinforced fabric layer includes afirst fabric member that is disposed at a 45 degree angle to a secondfabric member with respect to a weave pattern of the first and secondfabric members.
 40. The method of any one of claims 35 to 39, wherein athickness of the lip member is in a range of 0.60 inch (15.24 mm) to 1.2inches (30.48 mm).
 41. The method of any one of claims 35 to 40 whereina transition portion from the lip member to the flexible member includesan upper curvilinear path corresponding to the upper surface and a lowercurvilinear path corresponding to the lower surface.
 42. The method ofclaim 41, wherein the upper curvilinear path has a tighter curved paththan the lower curvilinear path.
 43. The method of any one of claims 41and 42, wherein the lip member transitions to the flexible member atsubstantially a mid-point of a side of the lip member.
 44. The method ofany one of claims 35 to 43, wherein the lip member defines asubstantially oval-shaped cross-sectional profile.
 45. The method ofclaim 44, wherein end points of the oval-shaped cross-section withrespect to a longitudinal axis of the oval-shaped cross-section arepinched to create the seal between the cover portion and the bodyportion.
 46. The method of claim 45, wherein the oval-shapedcross-section has a flattened profile on a side adjacent to the flexiblemember.
 47. The method of any one of claims 35 to 43, wherein the lipmember defines a substantially semicircle-shaped cross-sectionalprofile.
 48. The method of any one of claims 35 to 47, wherein the uppersurface of the flexible member has a substantially smooth wall portion.49. The method of claim 48, wherein the substantially smooth wallportion defines a substantially semi-spherical bowl.
 50. The method of48, wherein the substantially smooth wall portion circumscribes acentral portion.
 51. The method of claim 50, wherein a thickness of thecentral portion increases in a radial direction from the smooth wallportion to a center of the central portion such that the upper surfaceis flat along the central portion.